Vibrating member for a brushless vacuum cleaner

ABSTRACT

A vacuum cleaner includes a vacuum head having a housing and a vibrating member connected to the housing. A suction inlet draws dirt and debris into the vacuum head. Vibration of the vibrating member facilitates drawing the dirt and debris into the vacuum head through the suction inlet.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 61/775,268, filed Mar. 8, 2013, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a brushless vacuum cleaner having a vibrating member to facilitate removing dirt and debris from a surface to be cleaned. More particularly, the present invention relates to a brushless vacuum cleaner having a vibrating member vibrated by air drawn into a vacuum head. Still more particularly, the present invention relates to a brushless vacuum cleaner having an impeller for vibrating a vibrating member in which the impeller is driven by air passing therethrough.

BACKGROUND OF THE INVENTION

Conventional vacuum cleaners typically use a suction nozzle that is movable across a surface to be cleaned. The suction created at an inlet in the nozzle results in the removal of dirt and debris accumulated on the surface. However, ground-in dirt is frequently encountered when cleaning carpets or other textured surfaces, and reliance on suction for removal of such ground-in dirt has proven to be unsatisfactory.

Accordingly, effort has been made to provide vacuum cleaners with an effective means to agitate the carpet surface to dislodge ingrained dirt and debris. Such beaters are often located on the vacuum cleaner nozzle head, so that dirt can be dislodged and instantly removed by simply moving the nozzle head across a soiled carpet surface. The earliest known beaters are mechanical beaters, which physically strike the carpet surface to loosen dirt particles.

One example of a mechanical beater is a brush roll that agitates a surface to be cleaned to loosen dirt and debris therefrom that might not be removed from the surface by the suction force of the vacuum cleaner. The brush roll is driven by a motor disposed in the vacuum cleaner. The brush roll typically has a substantially cylindrical shape with a plurality of outwardly extending bristles. The motor rotates the brush roll such that the surface to be cleaned is agitated by the bristles moving over the surface.

However, the brush roll can cause wear of the surfaces being cleaned over time and can result in premature replacement thereof. Additionally, the brush roll also wears down over time, thereby requiring replacement.

Conventional brushless vacuum cleaners do not have a brush roll or the motor for driving the brush roll. The conventional brushless vacuum cleaners are lighter and do not wear down surfaces as vacuum cleaners having brush rolls. Accordingly, a need exists for a brushless vacuum cleaner having a vibrating member to facilitate removing dirt and debris from the surface being cleaned.

SUMMARY OF THE INVENTION

A brushless vacuum cleaner in accordance with exemplary embodiments of the present invention provides a vibrating member disposed in a vacuum cleaner head to facilitate removing dirt and debris from a surface to be cleaned. Dirt and debris loosened by the vibrating member can be lifted from the surface being cleaned by a suction inlet disposed in the vacuum head of the brushless vacuum cleaner, thereby increasing the efficiency of the brushless vacuum cleaner.

The brushless vacuum cleaner can have a suction inlet disposed in the vacuum cleaner head in any suitable position, such as, but not limited to, in the vibrating member, in the vibrating member, in front of the vibrating member, behind the vibrating member, or in front of and behind the vibrating member.

Other objects, advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, disclose preferred embodiments of the invention.

As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upwardly,” “downwardly,” and other orientational descriptors are intended to facilitate the description of the attachment assembly, and are not intended to limit the structure of the attachment assembly to any particular position or orientation.

BRIEF DESCRIPTION OF THE DRAWINGS

The above aspects and features of the present invention will be more apparent from the description for an exemplary embodiment of the present invention taken with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a vacuum cleaner head in accordance with an exemplary embodiment of the present invention;

FIG. 2 is a bottom perspective view of vibrating member of the vacuum cleaner head of FIG. 1;

FIG. 3 is a perspective view of the vacuum cleaner head of FIG. 1;

FIG. 4 is a side elevational view in cross-section of the vacuum cleaner head taken along line 4-4 of FIG. 3;

FIG. 5 is a side elevational view in cross-section of the vacuum cleaner of FIG. 1;

FIG. 6 is a perspective view of the vacuum cleaner head of FIG. 1 with a housing removed for clarity;

FIG. 7 is a lower perspective view of a brushless vacuum cleaner having a suction inlet disposed in front of and behind a vibrating member in accordance with a second exemplary embodiment of the present invention;

FIG. 8 is a lower perspective view of a brushless vacuum cleaner having a suction inlet disposed behind a vibrating member in accordance with a third exemplary embodiment of the present invention; and

FIG. 9 is a lower perspective view of a brushless vacuum cleaner having a suction inlet disposed in front of a vibrating member in accordance with a fourth exemplary embodiment of the present invention;

FIG. 10 is an exploded perspective view of a vibrating member of a brushless vacuum cleaner in accordance with a fifth exemplary embodiment of the present invention;

FIG. 11 is a perspective view of the vibrating member of FIG. 10;

FIG. 12 is an elevational view in cross section of the vibrating member of FIG. 11;

FIG. 13 is an elevational view in cross section of the vibrating member illustrating airflow therethrough;

FIG. 14 is an exploded perspective view of a suspension mounting bracket of the vibrating member;

FIG. 15 is an exploded perspective view of a partially assembled suspension mounting bracket of FIG. 14;

FIG. 16 is an exploded perspective view of the suspension mounting bracket partially connected to the vibrating member;

FIG. 17 is a perspective view of the suspension mounting bracket partially connected to the vacuum head of the vacuum cleaner;

FIG. 18 is an elevational view in cross section of the vibrating member connected to the vacuum head of the vacuum cleaner;

FIG. 19 is a perspective view of the vibrating member connected to the vacuum head of the vacuum cleaner;

FIG. 20 is an exploded perspective view of the vibration motor and vibrating member;

FIG. 21 is a perspective view of the assembled vibration motor and vibrating member of FIG. 20;

FIG. 22 is a perspective view of a brushless vacuum cleaner including a vibrating member of FIG. 10;

FIG. 23 is an exploded perspective view of a vacuum head of the vacuum cleaner of FIG. 22; and

FIG. 24 is a perspective view of a flexible hose connecting to a body of the vacuum cleaner of FIG. 22.

Throughout the drawings, like reference numerals will be understood to refer to like parts, components and structures.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

As shown in FIGS. 1-24, a brushless vacuum cleaner in accordance with exemplary embodiments of the present invention includes a vibrating member to facilitate removing dirt and debris from a surface to be cleaned. The vacuum cleaner can be any type of device employing suction to clean, including, but not limited to, upright, canister and handheld vacuum cleaners. The following description refers to a canister style vacuum cleaner.

A motor and a dirt and debris collector of a canister style vacuum cleaner 11 are housed in a separate unit (such as body 512 of FIG. 22), which is connected to a vacuum head 12 by a flexible hose 13, as shown in FIGS. 1 and 4. Wheels 16 connected to a housing 19 of the vacuum head 12 facilitate moving the vacuum head across a surface to be cleaned.

The vacuum cleaner 11 of the present invention does not include a brush roll in the vacuum head 12, as shown in FIGS. 2 and 4. The motor creates a partial vacuum, thereby creating a suction force at an inlet 14 in a lower surface 20 of the housing 19 of the vacuum head 12. The suction inlet 14 draws air through an opening or slot 18 in the vibrating member 15, such as a sonic bar assembly, movably connected to the lower surface 20 of the housing 19. Arrows 17 in FIG. 2 indicate the airflow through slots 18 in the vibrating member 15. The slots 18 are substantially rectangular and arranged in a 3×3 grid (FIG. 2) or a 3×4 grid (FIG. 6), although any suitable shape and configuration of the slots in the vibrating member 15 can be used.

As shown in FIG. 4, the vibrating member 15 preferably has a substantially rectangular shape with a plurality of slots 18 therein, although the vibrating member can have any suitable shape. The slots 18 extend completely through the vibrating member 15 and are in fluid communication with the suction inlet 14 to allow air to be drawn from outside the vacuum head 12 into a cavity 29 of the vacuum head housing 19. The vibrating member 15 is movably connected to the housing 19. An opening 21 in the lower surface 20 of the housing 19 receives the vibrating member 15. A plurality of spring members 22 are connected between an upper surface 23 of the vibrating member 15 and an inner surface 24 of the housing 19 to allow for vibrating movement of the vibrating member 15. Alternatively, a plurality of resilient members, such as rubber or silicone posts (for example, suspension assemblies 451 of FIG. 12), can be connected between the vibrating member 15 and the housing 19 to allow for vibrating movement of the vibrating member. Preferably, the spring members 22 are connected between mounting tabs 25 mounted on the upper surface 23 of the vibrating member 15 and mounting posts 26 connected to the inner surface 24 of the housing 19.

An impeller 27 is rotatably disposed in the cavity 29 of the vacuum head housing 19, as shown in FIGS. 4 and 5, and has a plurality of blades 28 rigidly connected thereto. A first shaft 30 is rigidly connected to the impeller 27, such that the first shaft 30 rotates with rotation of the impeller 27. The first shaft 30 is preferably coaxial with a rotation axis of the impeller 27. A second shaft 31 is rotatably connected to the first shaft 30. Preferably, the second shaft 31 is connected at substantially 90 degrees to the first shaft 30. A gear drive 32, such as a 90 degree gear drive including bevel gears or a soft coupling, is connected between the first and second shafts 30 and 31 to translate rotation of the first shaft 30 to rotation of the second shaft 31. Any suitable gear drive or coupling can be used that translates rotation of the first shaft 30 to rotation of the second shaft 31.

A cam member 33 is rigidly connected to the second shaft 31 at an opposite end from the gear drive 32. Preferably, the cam member 33 is an eccentric cam. The cam member 33 is disposed in a cam housing 34 rigidly fixed to the upper surface 23 of the vibrating member 15, as shown in FIGS. 4 and 5. The cam housing 34 is substantially tubular with the cam member 33 placed in the center opening, although other shapes may be used.

When air is drawn into the suction inlet 14 through the slots 18 in the vibrating member 15 as indicated by arrows 17, the air is directed to the blades 28 of the impeller 27 as indicated by arrows 35 in FIG. 6. The air passes through the impeller blades 28, thereby causing rotation of the impeller 27 in a counter-clockwise direction as indicated by arrow 36. The counter-clockwise rotation of the impeller 27 causes counter-clockwise rotation of the first shaft 30 as indicated by arrows 37. The counter-clockwise rotation of the first shaft 30 is translated into clockwise rotation of the second shaft 31, as indicated by arrow 38, by gear drive 32. The clockwise rotation of the second shaft 31 causes clockwise rotation of the cam member 33, which is rigidly connected to the second shaft. The rotation of the cam member 33 causes the cam member 33 to strike the cam housing 34 (FIGS. 4 and 5) rigidly connected to the upper surface 23 of the vibrating member 15. The striking of the cam housing 34 by the cam member 33 causes the vibrating member 15 to vibrate, which is further facilitated by the spring members 22 connecting the vibrating member 15 to the vacuum head housing 19. Accordingly, the vibrating member 15 is vibrated during operation of the vacuum cleaner 11 by drawing air into the vacuum head 12, such that a motor to vibrate the vibrating member 15 is not required.

Alternative embodiments of the vacuum head are shown in FIGS. 7-9. As shown in FIG. 7, a vacuum head 112 in accordance with a second exemplary embodiment of the present invention has a first suction inlet 113 disposed in front of a vibrating member 115 in a lower surface 119 of the vacuum head housing 120. A second suction inlet 114 is disposed behind the vibrating member 115. Arrows 116 indicate air flowing into the first suction inlet 113 in front of the vibrating member 115, and arrows 117 indicate air flowing into the second suction inlet 114. The operation and features of the vacuum head 112, with the exception of those noted above, in accordance with the second exemplary embodiment of the present invention are substantially similar to the operation of the vacuum head 12 in accordance with the first exemplary embodiment of the present invention.

As shown in FIG. 8, a vacuum head 212 in accordance with a third exemplary embodiment of the present invention has a suction inlet 214 disposed behind a vibrating member 215 in a lower surface 219 of the vacuum head housing 220. Arrows 217 indicate air flowing into the suction inlet 214 behind the vibrating member 215. The operation and features of the vacuum head 212, with the exception of those noted above, in accordance with the third exemplary embodiment of the present invention are substantially similar to the operation of the vacuum head 12 in accordance with the first exemplary embodiment of the present invention.

As shown in FIG. 9, a vacuum head 312 in accordance with a fourth exemplary embodiment of the present invention has a suction inlet 313 disposed in front of a vibrating member 315 in a lower surface 319 of the vacuum head housing 320. Arrows 316 indicate air flowing into the suction inlet 313 in front of the vibrating member 315. The operation and features of the vacuum head 312, with the exception of those noted above, in accordance with the fourth exemplary embodiment of the present invention are substantially similar to the operation of the vacuum head 12 in accordance with the first exemplary embodiment of the present invention.

A vibrating member 413 for a brushless vacuum cleaner 501 in accordance with a fifth exemplary embodiment of the present invention is shown in FIGS. 10-24. A suction inlet 419 draws air through the vibrating member 413, such as a sonic bar assembly. The vibrating member 413 is electrically powered by a motor 435 disposed in a vacuum head 423.

The vibrating member 413 includes a lower housing 431 connected to an upper housing 433, as shown in FIGS. 10-13 and 21, to form an airtight cavity 432. The motor 435 is connected to the lower housing 431 and electrically connected by wires 436 to a power supply. An enclosure 438 in the upper housing 433 receives the motor 435 when the upper and lower housings 431 and 433 are connected together. The motor 435 vibrates the vibrating member 413 when power is supplied thereto.

The electrical wires 436 of the motor are connected to an electrical connector 503 connected to the vacuum head 423, as shown in FIG. 23. A wand 505 has a mechanical fitting 506 at an end thereof that is receivable by a corresponding mechanical fitting 507 connected to the vacuum head 423. Mechanically connecting the corresponding fittings 506 and 507 results in an electrical connection between the electrical connector 503 of the vacuum head 423 and a corresponding electrical connector 508 connected to the wand 505. An electrical wire 509 runs along an inner surface of the wand 505 and an inner surface of a flexible hose 510 connected to the wand 505. A fitting 511 at an end of the flexible hose 510 allows the flexible hose to be connected to an opening 513 in a body 512 of the vacuum cleaner 501. The electrical wire 509 is electrically connected to the power supply for the vacuum cleaner 501 such that electrical power is supplied to the motor 435 of the vibrating member 413. A switch 514 can be electrically connected to the motor 435 to control the supply of power thereto. The wand 505 and flexible hose 510 provide an air flow path from the vacuum head 423 to the body 512 of the vacuum cleaner 501.

The motor 435 is fixed to the vibrating member 413, as shown in FIGS. 12, 13, 20 and 21. Preferably, the motor 435 is fixed by a bracket 446 to the lower housing 431. An off-center weight 491 is disposed on a motor shaft 493 to introduce a vibration when the shaft 493 rotates, as shown in FIGS. 20 and 21. An opening 447 in the housing enclosure 438 allows the off-center weight 491 and motor shaft 493 to pass through the enclosure 438. The vibration of the motor shaft 493 causes the motor 435 to vibrate. The vibration of the motor 435 is transferred to the lower housing 431 through the bracket 446. Fasteners 495 secure the bracket 446 to the vibrating member 413. A plurality of suspension assemblies 451 isolate the vibrating member 413 from a vacuum head 423 of the vacuum cleaner such that the vibrations are not transferred to the vacuum head 423. Suspension mounts 497, which are substantially similar to posts 471, connect the bracket 446 to the vacuum head 423.

A plurality of slots 437 are disposed in the lower housing 431 to allow air to be drawn in through the slots 437 to the suction inlet 419. Preferably, the slots 437 extend longitudinally across the lower housing 431, as shown in FIG. 10, although the slots can have any suitable shape or configuration. A flexible connector 441 connects the cavity 432 to the suction inlet 419, as shown in FIGS. 10-12.

The suction inlet 419 is associated with the vibrating member 413 and draws dirt and debris loosened by the vibrating member 413 through the slots 437 therein. The suction inlet 419 is in fluid communication with the vacuum air path 443, which is in fluid communication with a filter bag, dust bin or any other suitable debris collector.

A plurality of suspension assemblies 451 connect the vibrating member 413 to the vacuum head 423 of the vacuum cleaner, as best shown in FIGS. 14-19, to allow the vibrating member 413 to vibrate with respect to the vacuum head 423 of the vacuum cleaner. The suspension assembly 451 includes a suspension bracket 475, two posts 471 and a retaining member 473, as shown in FIGS. 14-16. The suspension bracket 475 has a pair of openings 480 disposed in a base 482. A bracket protrusion 481 extends upwardly from the base 482 between the pair of openings 480. An opening 490 is disposed in a free end of the bracket protrusion 481. A recess 461 in a lower surface 463 of the vacuum head 423 of the vacuum cleaner receives the vibrating member 413. A plurality of first openings 465 in the recess 461 receives posts 471 of the suspension members and a plurality of second openings 466 in the recess 461 receives retaining members 473 of the suspension assembly 451.

The posts 471 are substantially identical, as shown in FIG. 14. The post 471 includes an upper flange 483 axially spaced from a lower flange 484. An enlarged head portion 492 is axially spaced from the upper flange 483 such that the upper flange 483 is disposed between the enlarged head portion 492 and the lower flange 484. Preferably, the post 471 is made of a soft, flexible silicone, although any suitable material can be used. The post 471 is preferably a single, one-piece member.

The two posts 471 are inserted through a pair of openings 480 in the base 482 of the suspension bracket 475 such that upper and lower flanges 483 and 484 of the post 471 are disposed on opposite sides of the base 482 of the suspension bracket 475, as shown in FIGS. 15 and 18. The enlarged head portion 492 and the upper flange 483 are inserted through the opening 480 in the base 482. The posts 471 are made of a flexible material to allow the enlarged head portion 492 and the upper flange 483 to pass through the opening 480 without losing or distorting their original shape, as shown in FIGS. 15 and 16.

The suspension bracket 475 is placed over a center protrusion 476 extending outwardly from an inner surface 478 of the vibrating member 413. A pair of side protrusions 479 extend outwardly from the inner surface 478 on opposite sides of the center protrusion 476. The center protrusion 476 is received by the bracket protrusion 481 and the side protrusions 479 are received by the lower flanges 484 of the posts 471 and may extend through the openings 480 in the suspension bracket 475 and are received by the posts 475.

The posts 471 are passed through the first openings 465 in the vacuum head 423 and the bracket protrusion 481 is passed through the second opening 466, as shown in FIGS. 17 and 18. The upper flange 483 abuts an inner surface 488 of the vacuum head 423 when the posts 471 are fully inserted through the openings 465 as shown in FIG. 18. A retaining bushing 485 is secured to the bracket protrusion 481 by the retaining member 473, as shown in FIGS. 18 and 19. The retaining bushing 485 and the retaining member 473 are connected to the suspension assembly 451 from an outer surface 486 of the vacuum head 423, as shown in FIG. 18. An outer surface of the retaining bushing 485 engages the opening 466 in the vacuum head 423 and an inner surface of the retaining bushing 485 receives the bracket protrusion 481. The retaining member 473 engages the center protrusion 476 of the vibrating member 413 to further secure the vibrating member 413 to the vacuum head 423 of the vacuum cleaner 501. Preferably, the bushing 485 is made of silicone. However, any resilient, elastic, flexible or other suitable vibration-absorbing material may be used. The suspension assembly 451 isolates the vibration of the vibrating member 413 from the vacuum head 423 of the vacuum cleaner 501.

As shown in FIGS. 20 and 21, the suspension assembly 451 is disposed at each end of the vibrating member 413. Additionally, suspension mounts 497 are disposed on opposite sides of the motor enclosure 438 to further vibrationally isolate the vibrating member 413 from the vacuum head 423 of the vacuum cleaner 501. The suspension mounts 497 are substantially similar to the suspension posts 471, and are inserted through openings 498 in the bracket 446. Alternatively, as shown in FIGS. 10 and 11, only suspensions posts 471 disposed at opposite ends of the vibrating member 413 secure the vibrating member 413 to the vacuum head 423.

The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the scope of the present invention. Various modifications, alternatives and variations will be apparent to those of ordinary skill in the art, and are intended to fall within the scope of the invention as defined in the appended claims and their equivalents. 

What is claimed is:
 1. A vacuum cleaner, comprising: a vacuum head having a housing; a vibrating member connected to said housing; and a suction inlet to draw dirt and debris into said vacuum head; wherein said vacuum head does not have a brush roll and vibration of said vibrating member facilitates drawing the dirt and debris into said vacuum head through said suction inlet.
 2. The vacuum cleaner in accordance with claim 1, wherein at least one opening in said vacuum head is in fluid communication with said suction inlet.
 3. The vacuum cleaner in accordance with claim 2, wherein said at least one opening is disposed in said vibrating member.
 4. The vacuum cleaner in accordance with claim 2, wherein said at least one opening is disposed in said housing.
 5. The vacuum cleaner in accordance with claim 4, wherein first and second openings are disposed on opposite sides of said vibrating member.
 6. The vacuum cleaner in accordance with claim 1, wherein said vibrating member is vibrated by air drawn into said vacuum head.
 7. The vacuum cleaner in accordance with claim 1, wherein an impeller disposed in said housing is connected to said vibrating member such that air passing through said impeller causes vibration of said vibrating member.
 8. The vacuum cleaner in accordance with claim 7, further comprising a cam housing connected to said vibrating member; and a cam member disposed in said cam housing and connected to said impeller by a gear shaft, such that rotation of said impeller causes rotation of said cam member in said cam housing.
 9. The vacuum cleaner in accordance with claim 8, wherein said cam member strikes said cam housing when rotating therein, thereby vibrating said vibrating member.
 10. The vacuum cleaner in accordance with claim 1, wherein a plurality of spring members connect said vibrating member to said housing to vibrationally isolate said housing from said vibrating member.
 11. The vacuum cleaner in accordance with claim 1, wherein a motor is connected to said vibrating member to vibrate said vibrating member.
 12. The vacuum cleaner in accordance with claim 11, wherein an off-center weight is connected to a motor shaft of said motor to facilitate vibrating said vibrating member.
 13. The vacuum cleaner in accordance with claim 11, wherein a plurality of suspension assemblies connect said vibrating member to said housing to vibrationally isolate said housing from said vibrating member.
 14. The vacuum cleaner in accordance with claim 12, wherein a bracket connects said motor to said vibrating member.
 15. The vacuum cleaner in accordance with claim 14, wherein a plurality of suspension assemblies connect said bracket to said housing to vibrationally isolate said housing from said vibrating member.
 16. A vacuum cleaner, comprising: a vacuum head having a housing; a vibrating member connected to said housing; and a suction inlet to draw dirt and debris into said vacuum head; wherein vibration of said vibrating member facilitates drawing the dirt and debris into said vacuum head through said suction inlet, said vibrating member being vibrated by air drawn into said vacuum head.
 17. The vacuum cleaner in accordance with claim 16, wherein an impeller disposed in said housing is connected to said vibrating member such that air passing through said impeller causes vibration of said vibrating member.
 18. A vacuum cleaner, comprising: a vacuum head having a housing; a vibrating member connected to said housing; a motor connected to said vibrating member to vibrate said vibrating member; a suction inlet to draw dirt and debris into said vacuum head; and at least one opening in said vibrating member in fluid communication with said suction inlet; wherein said vacuum head does not have a brush roll and vibration of said vibrating member facilitates drawing the dirt and debris into said vacuum head through said at least one opening.
 19. The vacuum cleaner in accordance with claim 18, wherein an off-center weight is connected to a motor shaft of said motor to facilitate vibrating said vibrating member.
 20. The vacuum cleaner in accordance with claim 18, wherein a plurality of suspension assemblies connect said vibrating member to said housing to vibrationally isolate said housing from said vibrating member. 